Ceiling construction



March 12, 1963 Filed March 17, 1960 EPD.SFHPPEE ETAL CEILING CONSTRUCTION 2 Sheets-Sheet 1 INVENTORS EDGAR D. SHIPPEE. IT CK DVmscuooa ATTORNEY March 12, 1963 E. D. SHIPPEE ETAL 3,080,914

CEILING CONSTRUCTION 2 Sheets-Sheet 2 Filed March 1'7, 1960 INVENTORS EDGAR D. SHIPPE: BY J'AcK D.VERSCHOOR 3%,...

ATTORNEY United States Patent 3,080,914 CEILING CONSTRUCTION Edgar D. Shippee, Dunellen, and Jack D. Verschoor,

Martinsville, N.J., assignors to Johns-Manville Corporation, New York, N .Y., a corporation of New York Filed Mar. 17, 1960, Ser. No. 15,675 20 Claims. (Cl. 165-56) This invention relates to radiant heating or cooling systems for room interiors with provision being made for the absorption of sound; in particular, the invention comprises a ceiling formed from metallic pans having integral structure therein for the passage of heating or cooling fluid for heating or cooling a room interior, and the pans are of such a nature that they are capable of receiving or having superimposed thereover sound absorbing pads to absorb the sound waves emanating from a room interior.

An object of this invention is to provide a novel heating or cooling and sound absorbing system.

An additional object of this invention is to provide a novel combination heating or cooling and sound absorbing system exhibiting greater heat transfer characteristics than heating or cooling and sound absorbing systems utilized heretofore.

An additional object of this invention is to provide a novel heating or cooling and sound absorbing system wherein a direct molecular heat conductance path is provided between the heat transfer structure and selected portions of the system.

still an additional object of this invention is to pro vide anovel heating or cooling and sound absorbing system comprising a ceiling of juxtapositioned metallic pans with provision being made for removal of selected pans for purposes of inspection.

A further object of this invention is to provide a novel heating or cooling and sound absorbing system, of the type having metallic pans, with provision being made for molecular-direct heat conductance between the heat transfer structure and selected metallic pans and with additional provisions being made for conductance of heat to other pans not having molecular-direct heat conduct ance thereto.

A still further object of this invention is to provide a novel heating or cooling system comprising metallic pans having integral heating or cooling conduits therein with provision being made for novel interconnection between the integral conduits of such pans.

In brief, this invention comprises a novel heating or cooling and sound absorbing system having a plurality of metallic pans suspended from a basic structure to form a ceiling for a room interior. The selected pans are of such a nature that their upturned flanges have integral therewith conduits for the conduction of heat from the heating or cooling medium to the pans. In the preferred forms of construction, the pans are supported by a plurality of furring runners. Provision is made within the pans to accommodate the furring runners to allow for interconnection between the integral conduits of the selected pans, or provision is made in interconnecting conduits between the integral conduits of the selected pans to avoid the suspension system.

Also in the preferred forms of construction, the metallic pans are made forarninous so that sound absorbing pads can be situated Within the pans to receive the sound waves emanating from. a room interior and passing through the foramina or perforations in the metallic pans.

These and other objects will be readily apparent from- 3,080,914 Patented Mar. 12, 1963 ice the preceding brief description and the attached drawings wherein:

FIG. 1 is a perspective view of a ceiling construction embodying the present invention;

FIG. 2 is a view in cross-sectionalong section lines 22. of FIG. 1;

FIG. 3 is a view in perspective of an additional embodiment of a ceiling construction incorporating the instant invention therein;

FIG. 4 is a partial, cross-sectional view showing primarily a modification of the flanges of the pans used in the systems illustrated in FIGS. 1 and 3; and

FIG. 5 is a partial, cross-sectional view of another modification of the flanges of the pans utilized in either FIGS. 1 or 3. g

Referring to FIG. 1, the base structure -1 comprises the unfinished ceiling portion of a room interior, often referred to as the true ceiling thereof. The structure 1 may comprise a concrete slab or may be a finished ceiling which is to he remodeled or it may comprise an open latticework of girders, beams, or joists of a building. A plurality of channel members 2 are supported in any conventional manner, as, for example, by depending bars 3 secured to the channel members and to the base structure 1. The channel members 2 ordinarily extend from one end of a room compartment to the opposite end and are spaced a convenient distance apart so that the furring runners 4 may be supported therefrom. The latter comprise a plurality of T-bars extending transversely of the channel members 2 and are usually a butted thereagainst. A plurality of spring-type clips 4a engage the furring runners 4 and the channel members, thereby holding the runners resiliently biased against the channel members. Although'a T-type runner suspension system has been disclosed herein, it is to be understood that various other types of suspension systems may be utilized, as the furring runner and channel member system, described herein, is merely one of many well known suspension systems available on the commercial market at the present time.

The furring runners 4 are parallel to each other and are spaced a convenient center-to-center distance apart, ordinarily 2, 3, 4, or even 5 feet, depending upon the type of suspension system used, so that they receive and support the metallic panels or pan-s 7 which comprise the visible portion of the ceiling. The runners 4 have depending segments 5 extending therefrom With a bulbous area 6 incorporated therein.

The pans 7 have on opposite sides thereof upturned flanges 8 having beaded portions 9 therein which are retained by the bulbous areas 6 of the runners. The pans 7 are constructed of relatively thin metallic sheet stock as, for example, thin sheets of aluminum or copper; consequently, the upturned edges 8 are relatively resilient, and a spring-type action is obtained holding the bulbous area 9 firmly seat-ed within the portion 6 of runner 4. The manner of retention and suspension of the pans 7 by the runners 4 can also be modified in numerous ways, and, likewise, various types of pan suspension systems are available commercially.

The opposite pair of edges of selected pans, referring to FIGS.- 1 and 2, also are turned up to form end flanges 12. Incorporated therein is a bulbous area 13a formed by spacing the walls 13 within a localized area a conspacers tegral construction, since the wall members 13 and the flange 12. on one side of a selected pan are one continuous member, providing thereby a much greater efficiency of heat transference.

Ordinarily, the pans are aligned in rows running in both directions, i.e., the transverse and longitudinal directions of a room interior. Thus, in a particular row, the pans are of the type having integral conduits therein. Since, however, the suspension runners 4 are between the pans, the conduits 14 cannot be simply interconnected for serial movement of the heating or cooling fluid from one pan to an adjacent pan. Consequently, U-shape interconnecting conduits 15 are provided which circumvent the furring runners and interconnect the integral conduits of adjacent pans. At the point of entrance of each conduit 15 into an integral conduit 14, provision must be made for a. tight seal to prevent the escape of the heat transfer medium. This may be provided by a mechanical fastener, or, in the preferred form of construction, an end of an interconnected conduit 15 is soldered or brazed to the walls 13 of an adjacent conduit 14, as at 16.

Since a room ceiling is usually comprised of a plurality of rows of such pans and because of the high heat transfer rate of the present heating or cooling system, it is not necessary to provide for integral conduits 14 in each row of pans. Depending upon the heating or cooling requirements of a particular room compartment, the integral conduits may be provided in pans in every other row, or in every third or fourth row, as required. The end pans in each such predetermined conduit rows are interconnected to provide for a continuous conduit system running across the entire ceiling area (illustrated partially in FIG. 3). In relatively large room compartments, as, for example, a hall or the like, it may be necessary to interconnect the rows having the interconnected integral conduits so as to provide two or three independent flow systems.

The pans adjacent the selected rows, i.e., those rows having pans with integral conduits therein, are of conventional form and have their upturned flanges 12a merely abutting the flanges 12, so that the juxtapositioned pans are in heat conducting relationship. The opposite pair of flanges, of course, are shaped so as to be capable of being supported from the furring runners 4.

The pans 7, 7a, etc., in the preferred form of construction, have formed therein perforations 10 over the entire visible face thereof. Sound absorbing pads 11 are situated within each pan, and the sound waves, emanating from a room interior, pass through the perforations 10 and are absorbed by the pads 11.

It is thus seen that a highly eflicient heating or cooling and sound absorbing system has been provided, as compared to similar systems utilized heretofore. For purposes of heating a room interior, interconnecting conduits and integral conduits 14 have a hot fluid passing therethrough, as, for example, hot water or steam. The walls 13, being relatively thin, are quickly heated by the passing fluid and conduct their heat to the non-separated portions of the flanges 12, which in turn conduct the heat to the face port-ion of each panel 7. The heated panels 7 radiate heat to the room interior. Adjacent panels 7a, on either side of each panel 7, have their flanges 12a heated through thermal contact with flanges 12, which likewise conduct heat thereto, and each pair of panels 7a, on either side of a panel 7, also radiates heat to the room interior but not to an extent as great as the intermediate panel 7. The conduct-ion to the face of a panel 7 is at a much greater rate than to the face of an adjacent panel 711, since the heat is conducted, in a sense, by direct molecular action from the walls 13 to the integral portions of a flange 12' and the face of the panel; on the other hand, panel flange 12a receives its heat from flange 12, in a sense, indirectly, in that full face contact between the flanges must be made to obtain proper heat conduction therethrough. Such full face contact is quite difl'icult to obtain in actual practice, especially Where relatively thin metal sheets are utilized, as the very nature of the material creates high and low spots, even in small localized areas, so that heat conduction only passes through the high spots in direct contact with each other. Moreover, maximum heat conduction between adjacent contacting flanges can only be obtained if the adjacent contacting surfaces are clean at all times. Quite often, the exterior portion of the flanges is painted in a manner similar to the finish applied to the faces in the main body of the panels. This finish, together with any possible dirt, dust, or grime, appearing on the exterior portions of the flanges, reduces the proper heat conduction between the contacting surfaces or areas.

The eflicient heating or cooling system of the instant invention in no way interferes with the proper sound absorption of the sound waves emanating from the room interior, as the sound absorbing pads may be placed adjacent the faces of the panel-s 7 and 7a, so that the sound passed through the perforations 10 and 10a is properly received and absorbed by the pads.

In the event of malfunctions in any portion of the system, or of any equipment within the plenum chamber, it is readily evident that provision has been provided so that proper inspection of the plenum area between the panels 7 and 7a and the base structure 1 may be made. Thus, the panel-s 7a, for example, may be removed from within the ceiling area, since they are retained only by the spring clip action between the flanges and the depending portions 5 of runners 4.

Referring to FIG. 3, an additional embodiment is provided wherein provision is made within the panels to circumvent the furring runners 4. In this construction, the panels 27 are fabricated in the manner similar to the manner of fabricating the panels of FIG. 1. Thus, the face portions of the panels 27 have face perforations 30 therein allowing for the passage of sound waves therethrough to be thereby effectively absorbed by the sound absorbing pads 31. The end flanges 32 have a localized area therein wherein the wall portions 33 are spaced from each other to form an integral conduit 34 within at least a portion of the end flanges. The runners 24 are suspended from channel members and form a base structure in a manner similar to that illustrated in FIG. 1; the runners are of the type shown in FIG. 1 and have depending portions 25 with bulbous areas 26 therein for the receiving and containment of the opposite pair of end flanges of panel 27.

In order to accommodate the furring runners 24, the ends of the flanges'32 are cut away or receded as at 35b. Depending upon the height of the runners 24, the flanges 32 are made of such a height so as to have the conduits 34 higher than the top of the runners 24 or extending deeper into the plenum chamber and above the uppermost surface of runners 24. In this way, conduits 34 are situated above the top of runners 24 and are direct- 'ly in line so that a linear interconnecting conduit 35 may be inserted between adjacent pan conduits and soldered thereto, as at 36, to provide a proper seal therefor. The ends of the interconnecting conduits 35 and the integral conduits 34, now formed into a single linear conduit, may be interconnected by additional conduits 39 to provide a continuous flow arrangement between a selected number of such formed conduits.

The flanges 32a of an adjacent row of panels 27a have a part of their wall surface curved, as at 33a, conforming approximately to the curvature of walls 33. Thus, additional heat conductance contact is provided between the flanges 32a and 32, and since contact is provided adjacent wall areas 33, which, in turn, are in direct contact with the heating or cooling fluid, much greater conductance of heat is obtained as compared to the flange construction of FIG. 1. It is to be understood, however, that since integral conduits 34 may be provided only in every third or fourth row of aligned pans, depending upon the heating or cooling requirements of the particular room compartment, not all pans are in a position to receive heat from a conduit 34 or to transmit heat thereto. It is to be understood that the more rows of intervening pans, not having integral conduits therein, are provided, lesser is the effectiveness of the panels intermediate these selected rows. Thus, the primary effectiveness of the instant heating or cooling system is obtained by the panels 27 having integral conduits therein, and the panels 27a on each side of a row of panels 27.

The heating or cooling results in the instant embodiment of the invention are similar to those results obtained with the embodiment illustrated by FIG. 1; like.- wise, the sound absorption results are similar to those described with respect to the embodiment illustrated by FIG. 1.

The panels 27a are readily removable from the ceiling to provide access to the plenum chamber between the panels and the base structure, while the panels 27 are relatively fixed since the interconnecting conduits 35 are superposed over the furring runners 24. However, since the panels 27a may be removed from either side of panels 27, a complete inspection of the plenum chamber may be made. i

The embodiments of FIGS. 4 and 5 illustrate how the flanges may be modified in the ceilings of FIGS. 1 and 3 to obtain various degrees of heat conductance to adjacent panels from the panels having integral conduits therein. In the embodiment of FIG. 4, panels 47 having end flanges 52 and wall areas 53, providing conduits 54, have adjacent thereto panels 47a. The latter, in turn, have upturned flanges 52a with their upper portions forming a segment or are of a circle conforming approximately to the curvature of wall areas 53. In this way contact is obtained not only through the flanges 52. and 52a but also through a portion of wall 53 and flange ends 53a. Having flange ends 53a shaped in this manner, provision is made for additional heat conductance to panel 47a, and the construction does not impede the removal of panel 47a in the event such is required for purposes of inspection, for example.

In the embodiment illustrated in FIG. 5, panels 67 have end flanges 72 with Wall areas 73 at the ends thereof forming conduits 74. The outer ends of the flanges are machined off to provide a circular bulge, forming the conduit, at the end of each flange. Adjacent panels 67a have end flanges 72a attached thereto, the ends of which are approximately semi-circular conforming to the outer curvature of the wall areas 73. This construction provides for greater contact between flanges 72a, at the semi-circular portions 73a, and the wall areas 73 of the flange 72. The flanges 72a with the curved end portions 73a may be spring-like so that a tendency is created to bias the flanges 72a against walls 73 and the bottom portions of flanges 72 to provide for more intimate contact. On the other hand, the flanges 72a and attached curved end segments 73 may be relatively rigid, if so desired.

While the invention has been described in rather full detail, it will be understood that these details need not be strictly adhered to and that various changes and modifications may suggest themselves to one skilled in the art,

all falling within the scope of the invention as defined by the subjoined claims.

What we claim is:

l. A suspended ceiling construction comprising a suspension system, a plurality of metallic rectangular pans horizontally arranged to form a ceiling, each pan having a relatively planar face forming a basic visible component of said ceiling, said pans having their edges turned up at approximate right angles to the planar faces, each of said pans being supported by the suspension system by a portion of its turned-up edges, selected pans having other integral portions of their turned-up edges formed into tubular shape, conduit means interconnecting the tubular portions of the selected pans, and means to pass a heating or cooling fluid through the tubular portions and interconnecting conduits.

2. A suspended ceiling construction comprising a plurality of metallic pans arranged in adjacent rows, a suspension system, each of said pans having its end edges turned up from the body of the pan, each of said pans being supported by the suspension system by a portion of its turned-up edges, a tubular conduit forming an integral part of another portion of the upturned edges of selected pans, with the walls of said conduit being approximately one-half the thickness of the pan, tubular means interconnecting the pan conduits, and means to pass a heating or cooling fluid through the interconnected pan conduits and tubular means.

3. A suspended ceiling construction comprising a suspension system, a plurality of relatively thin metallic pans having upturned edges, each of said pans being supported by the suspension system by a portion of its upturned edges, the Walls of portions of the upturned edges of selected pans being spaced from each other a considerable distance to form integral conduits therein, conduit means to interconnect the integral conduits of said selected pans, and means to pass a heating or cooling fluid 7 through the interconnected integral conduits and conduit means. 7 4. A suspended ceiling construction comprising a suspension system, a plurality of relatively thin metallic pans having upturned edges, said pans being arranged in adjacent contacting rows, each of said pans being supported by the suspension system by a portion of its upturned edges, tubular conduits forming an integral part of another portion of the upturned edges of the pans in selected rows, the walls of said conduits being approximately one-half the thickness of the integral pans, tubular means interconnecting the adjacent pan conduits, means to pass a heating or cooling fluid through the interconnected tubular means and pan conduits, and the rows of pans immediately adjacent the selected rows having a portion of their upturned edges in heat-conducting contact with the adjacent pan conduits.

5. A suspended ceiling construction comprising a suspension system of a plurality of spaced, extended runner strips, a plurality of relatively thin metallic pans having upturned edges arranged in adjacent rows, each of said pans being supported by a pair of adjacent runner strips,

the Walls of portions of the upturned edges of selected yvherein the turned-up edges containing the integral conduits extend higher than they adjacent runner strips allowing for interconnection of adjacent integral conduits by approximately linear conduit means.

8. A suspended ceiling construction comprlsing a plur-ality of metallic pans arranged in adjacent rows, a suspension system, each of said pans having its end edges turned up from the body of the pan, each of said pans being supported by the suspension system by a portion of its upturned edges, tubular conduits forming an integral part of portions of the upturned edges of pans in selected rows, with the walls of each conduit of said conduits being approximately one-half the thickness of its integral pan, conduit means interconnecting the pan conduits, means to pass a heating or cooling fluid through the interconnected panel conduits and conduit means, and portions of the upturned edges of the pans in rows of pans adjacent the selected rows being adjacent said tubular conduits.

, 9. The suspended ceiling construction of claim 8 wherein said portions of the upturned edges of the pans in rows of pans adjacent the selected rows are in thermal contact with said tubular conduits.

10. The suspended ceiling construction of claim 9 wherein the integral tubular conduits are at the ends of their respective pan edges, and the portions of the upturned edges of the pans in rows of pans adjacent the selected rows are circumscribed about a portion of the integral conduits.

11. The suspended ceiling construction of claim 8 wherein the upturned edges of the pans in rows of pans adjacent the selected rows are spaced from the integral. conduits in the adjacent pans.

12. A combined radiant heating or cooling and acoustic system comprising a base structure, a suspension system secured thereto, a plurality of foraminous, metallic pans arranged to form a ceiling spaced from the base structure, each of said pans having upturned flanges, each of said pans being supported by the suspension system by a portion of its turned-up edges, selected panels having other integral portions of their upturned flanges formed into tubular shape, conduit means interconnecting the tubular portions of said selected panels, means to pass a heating or cooling fluid through the tubular portions and interconnecting conduits, and sound absorbing means situated between the formed ceiling and base structure.

13. A combined radiant heating or cooling and acoustic system comprising a base structure, a suspension system, a plurality of metallic, foraminous pans arranged in adjacent rows to form a ceilingyeach of said pans having upturned flanges, each of said pans being supported by the suspension system by a portion of its turnedup edges, tubular conduits forming an integral part of other portions of said upturned flanges, with the walls of said conduits being approximately one-half the thickness of the pans, tubular means interconnecting the pan conduits, means to pass a heating or cooling fluid through the interconnected pan conduits and tubular means, and sound absorbing means situated within the pans.

14. A combined radiant heating or cooling and acoustic system comprising a suspension system, a plurality of relatively thin, metallic, foraminous pans having upturned edges, each of said pans being supported by the suspension system by a portion of its upturned edges, the walls of portions of the upturned edges of selected pans being spaced from each other a considerable distance to form integral conduits therein, conduit means to interconnect the integral conduits of said selected pans, means to pass a heating or cooling fluid throughout the interconnected integral conduits and conduit means, and sound absorbing means situated Within at least most of the pans.

15. A combined radiant heating or cooling and acoustic system comprising a suspension system, a plurality of relatively thin, foraminous, metallic pans having upturned edges, said pans being arranged in adjacent contacting rows, each of said pans being supported by the suspension system by a portion of its upturned edges, tubular conduits forming an integral part of another portion of the upturned edges of the pans in selected rows, the Walls of said conduits being approximately one half the thickness of the integral panels, tubular means interconnecting the adjacent pan conduits, means to pass a heating or cooling fluid through the interconnected tubular means and pan conduits, the rows of panels immediately adjacent the selected rows having a portion of their upturned edges in heat contact with the adjacent pan conduits, and sound absorbing pads superposed over the metallic pans.

16. A combined radiant heating or cooling and acoustic system, comprising a suspension system of a plurality of spaced, extended runner strips, a plurality of relatively thin, foraminous, metallic pans arranged in adjacent roWs with each pan having upturned edges, each of said pans being supported by a pair of adjacent runner strips, the walls of portions of the upturned edges of selected pans being spaced from each other to form integral conduits within the pans, conduit means interconnecting adjacent integral conduits, means to pass a heating or cooling fluid through said interconnecting conduit means and integral conduits, said integral conduits extending in a general direction transverse to the lengths of the runner strips, and sound absorbing means superposed over the metallic pans.

17. The combined radiant heating or cooling and acoustic system of claim 16 wherein the interconnecting conduit means in a row of panels are curved to avoid adjacent runner strips.

18. The combined radiant heating or cooling and acoustic system of claim 16 wherein the turned up edges containing the integral conduits extend higher than the adjacent runner strips allowing for interconnection of adjacent integral conduits by approximately linear conduit means.

19. A combined radiant heating or cooling and acoustic system comprising a plurality of foraminous, metallic pans, arranged in adjacent rows, a suspension system, each of said pans having its end edges turned up from the body of the pan, each of said pans being supported by the suspension system by a portion of its upturned edges, tubular conduits forming an integral part of other portions of the upturned edges of pans in selected rows, with the walls of each conduit being approximately onehalf the thickness of its integral pan, conduit means interconnecting the pan conduits, means to pass a heating or cooling fiuid through the interconnecting pan conduits and conduit means, portions of the upturned edges of the pans in rows of pans adjacent the selected rows being adjacent said tubular conduits, and sound absorbing means superposed over said pans.

20. The combined radiant heating or cooling and acoustic system of claim 19, wherein said portions of the upturned edges of the pans in rows of pans adjacent the selected rows are in thermal contact with said tubular conduits.

Norris Sept. 12, 1939 Smith Aug. 14, 1945 

1. A SUSPENDED CEILING CONSTRUCTION COMPRISING A SUSPENSION SYSTEM, A PLURALITY OF METALLIC RECTANGULAR PANS HORIZONTALLY ARRANGED TO FORM A CEILING, EACH PAN HAVING A RELATIVELY PLANAR FACE FORMING A BASIC VISIBLE COMPONENT OF SAID CEILING, SAID PANS HAVING THEIR EDGES TURNED UP AT APPROXIMATE RIGHT ANGLES TO THE PLANAR FACES, EACH OF SAID PANS BEING SUPPORTED BY THE SUSPENSION SYSTEM BY A PORTION OF ITS TURNED-UP EDGES, SELECTED PANS HAVING OTHER INTEGRAL PORTIONS OF THEIR TURNED-UP EDGES FORMED INTO TUBULAR SHAPE, CONDUIT MEANS INTERCONNECTING THE TUBULAR PORTIONS OF THE SELECTED PANS, AND MEANS TO PASS A HEATING OR COOLING FLUID THROUGH THE TUBULAR PORTIONS AND INTERCONNECTING CONDUITS. 